US11885051B2 - Braiding machine and methods of use - Google Patents

Abstract

Systems and methods for forming a tubular braid are disclosed here-in. A braiding system configured in accordance with embodiments of the present technology can include, for example, an upper drive unit, a lower drive unit, a mandrel coaxial with the upper and lower drive units, and a plurality of tubes extending between the upper drive unit and the lower drive unit. Each tube can be configured to receive individual filaments for forming the tubular braid, and the upper and lower drive units can act in synchronization to move the tubes (and the filaments contained within those tubes) in three distinct motions: (i) radially inward toward a central axis, (ii) radially outward away from the central axis, and (iii) rotationally about the central axis, to cross the filaments over and under one another to form the tubular braid on the mandrel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 35 U.S.C. § 371 U.S. National Phase application of International Patent Application No. PCT/US2018/055780, titled “BRAIDING MACHINE AND METHODS OF USE,” filed Oct. 13, 2018, which claims the benefit of U.S. Provisional Patent Application No. 62/572,462, titled “BRAIDING MACHINE AND METHODS OF USE,” filed Oct. 14, 2017, the contents of which are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The present technology relates generally to systems and methods for forming a tubular braid of filaments. In particular, some embodiments of the present technology relate to systems for forming a braid through the movement of vertical tubes, each housing a filament, in a series of discrete radial and arcuate paths around a longitudinal axis of a mandrel.

BACKGROUND

Braids generally comprise many filaments interwoven together to form a cylindrical or otherwise tubular structure. Such braids have a wide array of medical applications. For example, braids can be designed to collapse into small catheters for deployment in minimally invasive surgical procedures. Once deployed from a catheter, some braids can expand within the vessel or other bodily lumen in which they are deployed to, for example, occlude or slow the flow of bodily fluids, to trap or filter particles within a bodily fluid, or to retrieve blood clots or other foreign objects in the body.

Some known machines for forming braids operate by moving spools of wire such that the wires paid out from each spool cross over/under one another. However, these braiding machines are not suitable for most medical applications that require braids constructed of very fine wires that have a low tensile strength. In particular, as the wires are paid out from the spools they can be subject to large impulses that may break the wires. Other known braiding machines secure a weight to each wire to tension the wires without subjecting them to large impulses during the braiding process. These machines then manipulate the wires using hooks other means for gripping the wires to braid the wires over/under each other. One drawback with such braiding machines is that they tend to be very slow, since the weights need time to settle after each movement of the filaments. Moreover, since braids have many applications, the specifications of their design—such as their length, diameter, pore size, etc.—can vary greatly. Accordingly, it would be desirable to provide a braiding machine capable of forming braids with varying dimensions, using very thin filaments, and at high speed.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Instead, emphasis is placed on illustrating clearly the principles of the present disclosure.

FIG.1 is an isometric view of a braiding system configured in accordance with embodiments of the present technology.

FIG.2 is an enlarged cross-sectional view of a tube of the braiding system shown inFIG.1 configured in accordance with embodiments of the present technology.

FIGS.3A and3B are a top view and an enlarged top view, respectively, of the upper drive unit of the braiding system shown inFIG.1 configured in accordance with embodiments of the present technology.

FIGS.4A-4E are enlarged, schematic views of the upper drive unit shown inFIGS.3A and3B at various stages in a method of forming a braided structure configured in accordance with embodiments of the present technology.

FIGS.5 and6 are enlarged schematic views of a drive unit of a braiding system configured in accordance with embodiments of the present technology.

FIGS.7 and8 are enlarged top views of cam rings configured in accordance with embodiments of the present technology.

FIG.9 is a display of user interface for a braiding system controller configured in accordance with embodiments of the present technology.

FIG.10 is an isometric of a portion of a mandrel of the braiding system shown inFIG.1 configured in accordance with embodiments of the present technology.

DETAILED DESCRIPTION

The present technology is generally directed to systems and methods for forming a braided structure from a plurality of filaments. In some embodiments, a braiding system according to present technology can include an upper drive unit, a lower drive unit coaxially aligned with the upper drive unit along a central axis, and a plurality of tubes extending between the upper and lower drive units and constrained within the upper and lower drive units. Each tube can receive the end of an individual filament attached to a weight. The filaments can extend from the tubes to a mandrel aligned with the central axis. In certain embodiments, the upper and lower drive units can act in synchronization to move the tubes (and the filaments contained within those tubes) in three distinct motions: (i) radially inward toward the central axis, (ii) radially outward away from the central axis, and (iii) rotationally about the central axis. In certain embodiments, the upper and lower drive units simultaneously move a first set of the tubes radially outward and move a second set of the tubes radially inward to “pass” the filaments contained with those tubes. The upper and lower drive units can further move the first of tubes—and the filaments held therein—past the second set of tubes to form, for example, an “over/under” braided structure on the mandrel. Because the wires are contained within the tubes and the upper and lower drive units act in synchronization upon both the upper and lower portion of the tubes, the tubes can be rapidly moved past each other to form the braid. This is a significant improvement over systems that do not move both the upper and lower portions of the tubes in synchronization. Moreover, the present systems permit for very fine filaments to be used to form the braid since tension is provided using a plurality of weights. The filaments are therefore not subject to large impulse forces during the braiding process that may break them.

As used herein, the terms “vertical,” “lateral,” “upper,” and “lower” can refer to relative directions or positions of features in the braiding systems in view of the orientation shown in the Figures. For example, “upper” or “uppermost” can refer to a feature positioned closer to the top of a page than another feature. These terms, however, should be construed broadly to include semiconductor devices having other orientations, such as inverted or inclined orientations where top/bottom, over/under, above/below, up/down, and left/right can be interchanged depending on the orientation.

FIG.1 is an isometric of a braiding system100 (“system100”) configured in accordance with the present technology. Thesystem100 includes aframe110, anupper drive unit120 coupled to theframe110, alower drive unit130 coupled to theframe110, a plurality of tubes140 (e.g., elongate housings) extending between the upper andlower drive units120,130 (collectively “drive units120,130”), and amandrel102. In some embodiments, thedrive units120,130 and themandrel102 are coaxially aligned along a central axis L (e.g., a longitudinal axis). In the embodiment illustrated inFIG.1, thetubes140 are arranged symmetrically with respect to the central axis L with their longitudinal axes parallel to the central axis L. As shown, thetubes140 are arranged in a circular array about the central axis L. That is, thetubes140 can each be spaced equally radially from the central axis L, and can collectively form a cylindrical shape. In other embodiments, thetubes140 can be arranged in a conical shape such that the longitudinal axes of thetubes140 are angled with respect to and intersect the central axis L. In yet other embodiments, thetubes140 can be arranged in a “twisted” shape in which the longitudinal axes of thetubes140 are angled with respect to the central axis L, but do not intersect the central axis L (e.g., the top ends of the tubes can be angularly offset from the bottom ends of the tubes with respect the central axis L).

Theframe110 can generally comprise a metal (e.g., steel, aluminum, etc.) structure for supporting and housing the components of thesystem100. More particularly, for example, theframe110 can include anupper support structure116 that supports theupper drive unit120, alower support structure118 that supports thelower drive unit130, abase112, and atop114. In some embodiments, thedrive units120,130 are directly attached (e.g., via bolts, screws, etc.) to the upper andlower support structures116,118, respectively. In some embodiments, thebase112 can be configured to support all or a portion of thetubes140. In the embodiment illustrated inFIG.1, thesystem100 includeswheels111 coupled to thebase112 of theframe110 and can, accordingly, be a portable system. In other embodiments, thebase112 can be permanently attached to a surface (e.g., a floor) such that thesystem100 is not portable.

Thesystem100 operates tobraid filaments104 loaded to extend radially from themandrel102 to thetubes140. As shown, eachtube140 can receive asingle filament104 therein. In other embodiments, only a subset of thetubes140 receive a filament. In some embodiments, the total number offilaments104 is one half the total number oftubes140 that house thefilament104. That is, thesame filament104 can have two ends, and twodifferent tubes140 can receive the different ends of the same filament104 (e.g., after thefilament104 has been wrapped around or otherwise secured to the mandrel102). In other embodiments, the total number offilaments104 is the same as the number oftubes140 that house afilament104.

Eachfilament104 is tensioned by a weight secured to a lower portion of thefilament104. For example,FIG.2 is an enlarged cross-sectional view of anindividual tube140. In the embodiment illustrated inFIG.2, thefilament104 includes anend portion207 coupled to (e.g., tied to, wrapped around, etc.) aweight241 positioned within thetube140. The weight141 can have a cylindrical or other shape and is configured to slide smoothly within thetube140 as thefilament104 is paid out during the braiding process. Thetubes140 can further include an upper edge portion (e.g., rim)245 that is rounded or otherwise configured to permit thefilament104 to smoothly pay out from thetube140. Thetubes140 constrain lateral or “swinging” movement of theweights241 andfilaments104 to inhibit significant swaying and tangling of these components along the full length of thefilaments104. This enables thesystem100 to operate at higher speeds compared to systems in which filaments and/or tensioning means are non-constrained along their full lengths. Specifically, filaments that are not constrained may sway and get tangled with each other if a pause or dwell time is not incorporated into the process so that the filaments can settle. In many applications, thefilaments104 are very fine wires that would otherwise require significant pauses for settling without the full-length constraint and synchronization of the present technology. In some embodiments, thefilaments104 are all coupled to identical weights to provide for uniform tensions within thesystem100. However, in other embodiments, some or all of thefilaments104 can be coupled to different weights to provide different tensions. Notably, theweights241 may be made very small to apply a low tension on thefilaments104 and thus allow for the braiding of fine (e.g., small diameter) and fragile filaments.

Referring again toFIG.1, and as described in further detail below with reference toFIGS.3A and3B, thedrive units120,130 control the movement and location of thetubes140. Thedrive units120,130 are configured to drive thetubes140 in a series of discrete radial and arcuate paths relative to the central axis L that move thefilaments104 in a manner that forms a braided structure105 (e.g., a woven tubular braid; “braid105”) on themandrel102. In particular, thetubes140 each have anupper end portion142 proximate theupper drive unit120 and alower end portion144 proximate thelower drive unit130. Thedrive units120,130 work in synchronization to simultaneously drive theupper end portion142 and the lower end portion144 (collectively “endportions142,144”) of eachindividual tube140 along the same path or at least a substantially similar spatial path. By driving bothend portions142,144 of theindividual tubes140 in synchronization, the amount of sway or other undesirable movement of thetubes140 is highly limited. As a result, thesystem100 reduces or even eliminates pauses during the braiding process to allow the tubes to settle, which enables thesystem100 to be operated at higher speeds than conventional systems.

In some embodiments, thedrive units120,130 are substantially identical and include one or more mechanical connections so that they move identically (e.g., in synchronization). For example, jackshafts113 can mechanically couple corresponding components of the inner and outer drive mechanisms of thedrive units120,130. Similarly, in some embodiments, one of thedrive units120,130 can be an active unit while the other of thedrive units120,130 can be a slave unit driven by the active unit. In other embodiments, rather than a mechanical connection, an electronic control system coupled to thedrive units120,130 is configured to move thetubes140 in an identical sequence, spatially and temporally. In certain embodiments, where thetubes140 are arranged conically with respect to the central axis L, thedrive units120,130 can have the same components but with varying diameters.

In the embodiment illustrated inFIG.1, themandrel102 is attached to apull mechanism106 configured to move (e.g., raise) themandrel102 along the central axis L relative to thetubes140. Thepull mechanism106 can include a shaft108 (e.g., a cable, string, rigid structure, etc.) that couples themandrel102 to an actuator or motor (not pictured) for moving themandrel102. As shown, thepull mechanism106 can further include one or more guides109 (e.g., wheels, pulleys, rollers, etc.) coupled to theframe110 for guiding theshaft108 and directing the force from the actuator or motor to themandrel102. During operation, themandrel102 can be raised away from thetubes140 to extend the surface for creating thebraid105 on themandrel102. In some embodiments, the rate at which themandrel102 is raised can be varied in order to vary the characteristics of the braid105 (e.g., to increase or decrease the braid angle (pitch) of thefilaments104 and thus the pore size of the braid105). The ultimate length of the finished braid depends on the available length of thefilaments104 in thetubes140, the pitch of the braid, and the available length of themandrel102.

In some embodiments, themandrel102 can have lengthwise grooves along its length to, for example, grip thefilaments104. Themandrel102 can further include components for inhibiting rotation of themandrel102 relative to the central axis L during the braiding process. For example, themandrel102 can include a longitudinal keyway (e.g., channel) and a stationary locking pin slidably received in the keyway that maintains the orientation of themandrel102 as it is raised. The diameter of themandrel102 is limited on the large end only by the dimensions of thedrive units120,130, and on the small end by the quantities and diameters of thefilaments104 being braided. In some embodiments, where the diameter of themandrel102 is small (e.g., less than about 4 mm), thesystem100 can further include one or weights coupled to themandrel102. The weights can put themandrel102 under significant tension and prevent thefilaments104 from deforming themandrel102 longitudinally during the braiding process. In some embodiments, the weights can be configured to further inhibit rotation of themandrel102 and/or replace the use of a keyway and locking pin to inhibit rotation.

Thesystem100 can further include a bushing (e.g., ring)117 coupled to theframe110 via anarm115. Themandrel102 extends through thebushing117 and thefilaments104 each extend through an annular opening between themandrel102 and thebushing117. In some embodiments, thebushing117 has an inner diameter that is only slightly larger than an outer diameter of themandrel102. Therefore, during operation, thebushing117 forces thefilaments104 against themandrel102 such that thebraid105 pulls tightly against themandrel102. In some embodiments, thebushing117 can have an adjustable inner diameter to accommodate filaments of different diameters. Similarly, in certain embodiments, the vertical position of thebushing117 can be varied to adjust the point at which thefilaments104 converge to form thebraid105.

FIG.3A is a top view of theupper drive unit120 shown inFIG.1 in accordance with embodiments of the present technology, andFIG.3B is an enlarged top view of a portion of theupper drive unit120 shown inFIG.3A. While theupper drive unit120 is illustrated inFIGS.3A and3B, thelower drive unit130 can have substantially the same or identical components and functions as theupper drive unit120. Accordingly, the following description can apply equally to thelower drive unit130. Referring toFIGS.3A and3B together, theupper drive unit120 includes anouter assembly350 and an inner assembly370 (collectively “assemblies350,370”) arranged concentrically about the central axis L (FIG.1). Theassemblies350,370 include top plates which define an upper surface of theupper drive unit120 and cover the internal components of theassemblies350,370. However, the upper plates of theassemblies350,370 are not shown inFIGS.3A and3B to more clearly illustrate the operation of theassemblies350,370.

Theouter assembly350 includes (i) outer slots (e.g., grooves)354, (ii) outer drive members (e.g., plungers)356 aligned with and/or positioned within correspondingouter slots354, and (iii) an outer drive mechanism configured to move theouter drive members356 radially inward through theouter slots354. The number ofouter slots354 can be equal to the number oftubes140 in thesystem100, and theouter slots354 are configured to receive a subset of thetubes140 therein. In certain embodiments, theouter assembly350 includes 48outer slots354. In other embodiments, theouter assembly350 can have a different number ofouter slots354 such as 12 slots, 24 slots, 96 slots, or any other preferably even number of slots. Theouter assembly350 further includes alower plate351bopposite the upper plate. In some embodiments, thelower plate351bcan be attached to theupper support structure116 of theframe110.

In the embodiment illustrated inFIGS.3A and3B, the outer drive mechanism of theouter assembly350 includes anouter cam ring352 positioned between the upper and lower plates and rotatable relative to the upper and lower plates. An outer cam ring motor (e.g., an electric motor) can be configured to drive the firstouter cam ring352 to move a first set of theouter drive members356 radially inward to thereby move a first set of thetubes140 positioned in theouter slots354 radially inward. More particularly, the first outercam ring motor358 can be coupled to one or more pinions configured to engage atrack359 on theouter cam ring352. In some embodiments, as shown inFIG.3A, thetrack359 extends only partially around the perimeter of theouter cam ring352. Accordingly, in such embodiments, theouter cam ring352 is not configured to fully rotate about the central axis L. Rather, theouter cam ring352 moves through only a relatively small arc length (e.g., about 1°-5°, about 5°-10°, or about 1020 -20°) about the central axis L. In operation, theouter cam ring352 can be rotated in a first direction and a second direction (e.g., by reversing the motor) through the relatively small arc length. In other embodiments, thetrack359 extends around a larger portion of the perimeter, such as the entire perimeter, of theouter cam ring352, and theouter cam ring352 can be rotated more fully (e.g., entirely) about the central axis L.

As further shown inFIGS.3A and3B, thelower plate351bhas aninner edge363 that defines acentral opening364. A plurality ofwall portions362 are arranged circumferentially around thelower plate351band extend radially inward beyond theinner edge363 of thelower plate351b. Each pair ofadjacent wall portions362 defines one of theouter slots354 in thecentral opening364. Thewall portions362 can be fastened to thelower plate351b(e.g., using bolts, screws, welding, etc.) or integrally formed with thelower plate351b. In other embodiments, all or a portion of thewall portions362 can be on the upper plate (not shown) rather than thelower plate351bof theouter assembly350.

Theouter cam ring352 includes aninner surface365 having a periodic (e.g., oscillating) shape including a plurality ofpeaks367 andtroughs369. In the illustrated embodiment, theinner surface365 has a smooth sinusoidal shape, while in other embodiments, theinner surface365 can have other periodic shapes such as a saw-tooth shape, trapezoidal, linear trapezoidal, or any cut pattern containing a transition between a peak and a valley (for example, any of the patterns illustrated inFIGS.7 and8). Theouter cam ring352 is rotatably coupled to thelower plate351bsuch that the outer cam ring and thelower plate351bcan rotate with respect to each other. For example, in some embodiments, the rotatable coupling comprises a plurality of bearings disposed in a first circular channel (obscured inFIGS.3A and3B) formed between thelower plate351band thecam ring352. In the illustrated embodiment, theouter cam ring352 includes a secondcircular channel361 for rotatably coupling theouter cam ring352 to the upper plate via a plurality of bearings. In some embodiments, the first circular channel can be substantially identical to the secondcircular channel361.

As further shown inFIGS.3A and3B, theouter drive members356 are positioned in betweenadjacent wall portions362. Each of theouter drive members356 is identical, and each comprise abody portion392 coupled to apush portion394. Thepush portions394 are configured to engage (e.g., contact and push) tubes positioned within theouter slots354. Thebody portions392 include abearing395 that contacts the periodicinner surface365 of theouter cam ring392. Theouter drive members356 can each be slidably coupled to aframe396 that is attached to thelower plate351b, and biasing members398 (e.g., spring) extend between eachouter drive member356 and thecorresponding frame396. The biasingmembers398 exert a radially outward biasing force against theouter drive members356.

In operation, theouter drive members356 are driven radially inward by rotation of the periodicinner surface365 of theouter cam ring352, and returned radially outward by the biasingmembers398. Theinner surface365 is configured such that when thepeaks367 are radially aligned with a first set (e.g., alternating ones) of theouter drive members356, thetroughs369 are radially aligned with a second set (e.g., the other alternating ones) of theouter drive members356. Accordingly, as seen inFIGS.3A and3B, the first set ofouter drive members356 can be in a radially extended position, while the second set ofouter drive members356 are in a radially retracted position. In this position, thebody portions392 of the first set ofouter drive members356 are at or nearer to thepeaks367 than thetroughs369 of theinner surface365, and thebody portions392 of the second set ofouter drive members356 are at or nearer to thetroughs369 than thepeaks367. To move the second set ofouter drive members356 radially inward, and move the first set ofouter drive members356 radially outward, rotation of theouter cam ring352 moves thepeaks367 of theinner surface365 into radial alignment with the second set ofouter drive members356. Since the outward force of the biasingmembers398 urges theouter drive members356 into continuous contact with theinner surface365, the second set ofouter drive members356 move radially inward as theinner surface365 rotates to align thepeaks367 with the second set ofouter drive members356. Synchronously, the radially outward biasing force of the biasingmembers398 retracts the first set ofouter drive members356 into the space provided by thetroughs369.

Theinner assembly370 includes (i) inner slots (e.g., grooves)374, (ii) inner drive members (e.g., plungers)376 aligned with and/or positioned within corresponding ones of theinner slots374, and (iii) an inner drive mechanism configured to move theinner drive members376 radially outward through theinner slots374. As shown, the number ofinner slots374 can be equal to the number of outer of outer slots354 (e.g., 48 inner slots374) such that theinner slots374 can be aligned with theouter slots354. Theinner assembly370 can further include alower plate371bthat is rotatably coupled to aninner support member373. For example, in some embodiments, the rotatable coupling comprises a plurality of bearings disposed in a circular groove formed between theinner support member373 and thelower plate371b.

In the embodiment illustrated inFIGS.3A and3B, the inner drive mechanism comprises aninner cam ring372 positioned between the upper and lower plates. An innercam ring motor378 is configured to drive (e.g., rotate) theinner cam ring372 to move a first set of theinner drive members376 radially inward to thereby move a second set of thetubes140 positioned in theinner slots374 radially outward. The innercam ring motor378 can be generally similar to the outercam ring motors358. For example, the innercam ring motor378 can be coupled to one or more pinions configured to engage (e.g., mate with) a corresponding track on an inner surface theinner cam ring372. In some embodiments, the track extends around only a portion of an inner perimeter of theinner cam ring372, and the innercam ring motor378 is rotatable in a first direction and a second opposite direction to drive theinner cam ring372 through only a relatively small arc length (e.g., about 1°-5°, about 5°-10°, or about 10°-20°) about the central axis L.

Theinner assembly370 further includes aninner assembly motor375 configured to rotate theinner assembly370 relative to theouter assembly350. This rotation allows for theinner slots374 to be rotated into alignment with differentouter slots354. The operation of theinner assembly motor375 can be generally similar to that of the outercam ring motor358 and the innercam ring motor378.

As further shown inFIGS.3A and3B, thelower plate371bhas anouter edge383, and theinner assembly370 includes a plurality ofwall portions382 arranged circumferentially about thelower plate371band extending radially outward beyond the outer edge583. Each pair ofadjacent wall portions382 defines one of theinner slots374. Thewall portions382 can be fastened to thelower plate371b(e.g., using bolts, screws, welding, etc.) or integrally formed with thelower plate371b. In other embodiments, at least some of thewall portions382 are on the upper plate rather than thelower plate371bof theinner assembly370.

Theinner cam ring372 includes anouter surface385 having a periodic (e.g., oscillating) shape including a plurality ofpeaks387 andtroughs389. In the illustrated embodiment, theouter surface385 includes a plurality of linear ramps, while in other embodiments, theouter surface385 can have other periodic shapes such as a smooth sinusoidal shape, saw-tooth shape, etc. (for example, any of the patterns illustrated inFIGS.7 and8). Theinner cam ring372 is rotatably coupled to thelower plate371bby, for example, a plurality of ball bearings disposed in a first circular channel (obscured in the top views ofFIGS.3A and3B) formed between thelower plate371band theinner cam ring372. In the illustrated embodiment, theinner cam ring372 includes a secondcircular channel381 for rotatably coupling theinner cam ring372 to the upper plate via, for example, a plurality of ball bearings. In some embodiments, the first circular channel can be substantially identical to the secondcircular channel381. Theinner cam ring372 can accordingly rotate with respect to the upper and lower plates.

As further shown inFIGS.3A and3B, theinner drive members376 are coupled to thelower plate371bbetweenadjacent wall portions382. Each of theinner drive members376 is identical, and theinner drive members376 can be identical to theouter drive members356. For example, as described above, each of theinner drive members376 can have abody portion392 and apush portion394, and can be slidably coupled toframes396 mounted to thelower plate371b. Likewise, biasingmembers398 extending between eachinner drive member356 and theircorresponding frame396 exert a radially inward biasing force against theinner drive members376. As a result, theinner drive members376 continuously contact theouter surface385 of theinner cam ring372.

In operation, similar to theouter drive members356, theinner drive members376 are driven radially outward by rotation of the periodicouter surface385 of theinner cam ring372, and returned radially inward by the biasingmembers398. Theouter surface385 is configured such that when thepeaks387 are radially aligned with a first set (e.g., alternating ones) of theinner drive members376, thetroughs389 are radially aligned with a second set (e.g., the other alternating ones) of theinner drive members376. Accordingly, as seen inFIGS.3A and3B, the first set ofinner drive members376 can be in a radially extended position, while the second set ofinner drive members376 are in a radially retracted position. In this position, thebody portions392 of the first set ofinner drive members376 are at or nearer to thepeaks387 than thetroughs389 of theouter surface385, and thebody portions392 of the second set ofinner drive members376 are at or nearer to thetroughs389 than thepeaks387. To move the second set ofinner drive members376 radially outward, and move the first set ofinner drive members376 radially inward, rotation of theinner cam ring372 moves thepeaks387 of theouter surface385 into radial alignment with the second set ofinner drive members376. Since the inward force of the biasingmembers398 urges theinner drive members376 into continuous contact with theouter surface385, the second set ofinner drive members376 move radially outward as theouter surface385 rotates to align thepeaks387 with the second set ofinner drive members376. Synchronously, the radially inward biasing force of the biasingmembers398 retracts the first set ofinner drive members376 into the space provided by thetroughs389.

As illustrated inFIGS.3A and3B, theassemblies350,370 are configured such that when anouter drive member356 is in an extended position, an alignedinner drive member376 is correspondingly in a retracted position. In this manner, theassemblies350,370 maintain a constant amount of space for thetubes140. This keeps thetubes140 moving in a discrete, predictable pattern determined by a control system of thesystem100.

Notably, each of the drive members in thesystem100 is actuated by the rotation of a cam ring that provides a consistent and synchronized actuation force to all of the drive members. In contrast, in conventional systems where filaments are actuated individually or in small sets by separately controlled actuators, if one actuator is out of synchronization with another, there is a possibility of tangling of filaments. Moreover, because the number ofinner slots374 andouter slots354 is the same, half the tubes can be passed from theinner slots374 to theouter slots354, and vice versa, simultaneously. Likewise, the use of a single cam ring for actuating all of the outer drive members, and a single cam ring for actuating all of the inner drive members, significantly simplifies the design. In other configurations, the inner and outer cams can each contain multiple individually controlled plates: one cam per set per inner/outer assembly. Using multiple cams per inner/outer assembly allows increased control of tube movement and timing. These alternative configurations would also allow for both sets to be entirely loaded into either the inner or outer ring all at once, if necessary (as shown in, for example,FIGS.5 and6).

Thelower drive unit130 has components and functions that are substantially the same as or identical to theupper drive unit120 described in detail above with reference toFIG.3. The inner drive mechanisms (e.g., inner cam rings) of thedrive units120,130 move in a substantially identical sequence both spatially and temporally to drive the upper portion and lower portion of eachindividual tube140 along the same or a substantially similar spatial path. Likewise, the outer drive mechanisms (outer cam rings) of thedrive units120,130 move in a substantially identical sequence both spatially and temporally.

In general, theupper drive unit120 is configured to drive a first set of thetubes140 in three distinct movements: (i) radially inward (e.g., from theouter slots354 to the inner slots374) via rotation of theouter cam ring352 of theouter assembly350; (ii) radially outward (e.g., from theinner slots374 to the outer slots354) via rotation of theinner cam ring372 of theinner assembly370; and (iii) circumferentially relative to a second set of thetubes140 via rotation of theinner assembly370. Moreover, as explained in more detail below with reference toFIG.9, in some embodiments these movements can be mechanically independent and a system controller (not pictured; e.g., a digital computer) can receive input from a user via a user interface indicating one or more operating parameters for these movements as well as the movement of the mandrel102 (FIG.1). For example, the system controller can drive each of the three motors in thedrive units120,130 (e.g., the outercam ring motor358, the innercam ring motor378, and the inner assembly motor375) with closed loop shaft rotation feedback. The system controller can relay the parameters to the various motors (e.g., via a processor), thereby allowing manual and/or automatic control of the movements of thetubes140 and themandrel102 to control formation of thebraid105. In this way thesystem100 can be parametric and many different forms of braid can be made without modification of thesystem100. In other embodiments, the various motions of thedrive units120,130 are mechanically sequenced such that turning a single shaft indexes thedrive units120,130 through an entire cycle.

FIGS.4A-4E are schematic views more particularly showing the movement of eighttubes140 within theupper drive unit120 at various stages in a method of forming a braided structure (e.g., the braid105) in accordance with embodiments of the present technology. While reference is made to the movement of the tubes within theupper drive unit120, the illustrated movement of the tubes is substantially the same in thelower drive unit130 since the motions and components of thedrive units120,130 are identical. Moreover, while only eight tubes are shown inFIGS.4A-4E for ease of explanation and understanding, one skilled in the art will readily understand that the movement of the eight tubes is representative of any number of tubes (e.g., 24 tubes, 48 tubes, 96 tubes, or other numbers of tubes).

Referring first toFIG.4A, thesystem100 is an initial position in which (i) theouter assembly350 contains a first set oftubes440a(each labeled with an “X”), and the (ii) theinner assembly370 contains a second set oftubes440b(each labeled with an “O”). The first set oftubes440aare positioned within alternating ones of the outer slots354 (e.g., in theouter slots354 labeled A, C, E, and G), and the second set oftubes440bare positioned within alternating ones of the inner slots374 (e.g., in the inner slots labeled T, V, X, and Z). As shown, the first set oftubes440aare radially aligned with empty ones of the inner slots374 (e.g., with theinner slots374 labeled S, U, W, and Y). Similarly, the second set oftubes440bare radially aligned with empty ones of the outer slots354 (e.g., with the outer slots labeled B, D, F, and H). The reference numerals “X” for the first set oftubes440a, “O” for the second set oftubes440b, “A-H” for theouter slots354, and “S-Z” for theinner slots374 are reproduced in each ofFIGS.4A-4E in order to illustrate the relative movement ofassemblies350,370.

Referring next toFIG.4B, theinner assembly370 is rotated in a first direction (e.g., in the counterclockwise direction indicated by the arrow CCW) to align the second set oftubes440bwith a different set ofouter slots354. In the embodiment illustrated inFIG.4B, theinner assembly370 rotates relative to theouter assembly350 to align each tube in the second set oftubes440bwith the next availableouter slot354 that is empty—i.e., anouter slot354 that is two slots away. For example, while theinner slot374 labeled X was initially aligned with the emptyouter slot374 labeled F (FIG.4A), after rotation, theinner slot374 labeled X is aligned with the emptyouter slot354 labeled D. This step passes the filaments in the second set oftubes440bunder the filaments in the first set oftubes440ato create the weave pattern of the cylindrical braid. In some embodiments, theinner assembly370 can be rotated to align the second set oftubes440bwith empty ones of theouter slots354 that are not the next available empty outer slot354 (e.g.,outer slots354 that are four slots away, six slots away, etc.). The number of emptyouter slots354 skipped during rotation of theinner assembly370 determines the weave pattern of the resulting braid (e.g., 1 over 1, 1 over 2, 2 over 2, etc.). In some embodiments, instead of rotating theinner assembly370, theouter assembly350 is rotated. In some embodiments, the drive unit can rotate one of the sets of tubes only one or two empty spaces in either direction during a single rotation. Nevertheless, if required, the program controlling thesystem100 can achieve any number of passed spaces with multiple drop-offs and pick-ups of the same set, repeatedly. In other configurations, the drive units can be designed to mechanically achieve the same increase in rotational travel without programming assistance.

Referring next toFIG.4C, the first and second set oftubes440a,440bare “passed” by each other. More particularly, the first set oftubes440aare moved radially inward from theouter slots354 to theinner slots374, and the second set oftubes440bare simultaneously or substantially simultaneously moved radially outward from theinner slots374 to theouter slots354. For example, as described with reference toFIGS.3A and3B, a first set ofouter drive members354 of theouter assembly350 can be driven radially inward by theouter cam ring352 to move the first set oftubes440afrom theouter slots354 to theinner slots374. At the same time, a first set ofinner drive members376 of theinner assembly370 can be retracted radially inward to provide space for the first set oftubes440a. Likewise, a second set ofinner drive members376 of the inner assembly can be driven radially outward by theinner cam ring372 to move the second oftubes440bfrom theinner slots374 to theouter slots354. At the same time, a second set ofouter drive members356 can be retracted radially outward to provide space for the second set oftubes440b.

Next, as shown inFIG.4D, theinner assembly370 is rotated in a second direction (e.g., in the clockwise direction indicated by the arrow CW) to align the first set oftubes440awith a different set ofouter slots354. In the embodiment illustrated inFIG.4D, theinner assembly370 rotates relative to theouter assembly350 to align each tube in the first set oftubes440awith the next availableouter slot354 that is empty—i.e., anouter slot354 that is two slots away. For example, while theinner slot374 labeled W was initially aligned with the emptyouter slot374 labeled C (FIG.4C), after rotation, theinner slot374 labeled W is aligned with the emptyouter slot354 labeled E. This step passes the filaments in the first set oftubes440aunder the filaments in the second set oftubes440bto create the weave pattern of the cylindrical braid. In some embodiments, the amount of rotation can vary (e.g., rotation by more than one empty outer slot354). In the illustrated embodiment, after rotation, theinner assembly370 andouter assembly350 are in the initial or starting position, as illustrated inFIG.4A.

Finally, referring toFIG.4E, the first and second set oftubes440a,440bare “passed” by each other. More particularly, the second set oftubes440bare moved radially inward from theouter slots354 to theinner slots374, and the first set oftubes440aare simultaneously or substantially simultaneously moved radially outward from theinner slots374 to theouter slots354. As shown, each tube in the first set oftubes440ahas been rotated in the first direction (e.g., rotated twoouter slots354 in the clockwise direction) relative to the initial position shown inFIG.4A, and each tube in the second set oftubes440bhas been rotated in the second direction (e.g., rotated twoinner slots374 in the counterclockwise direction) relative to the initial position ofFIG.4A.

The steps illustrated inFIGS.4A-4E can subsequently be repeated to form a cylindrical braid on the mandrel as the first and second sets oftubes440a,440b—and the filaments held therein—are repeatedly passed by each other, rotating in opposite directions, sequentially alternating between radially outward passes relative to the other set and radially inward passes relative to the other set. One skilled in the art will recognize that the direction of rotation, the distance of each rotation, etc., can be varied without departing from the scope of the present technology.

FIGS.5 and6 are schematic views of a drive unit520 (e.g., an upper or lower drive unit) of a braiding system configured in accordance with another embodiment of the present technology. Thedrive unit520 can include features generally similar to thedrive units120,130 described in detail above with reference toFIGS.1-4E. For example, thedrive unit520 includes anouter assembly550 and inner assembly570 (collectively “assemblies550,570”) arranged coaxially within theouter assembly550. Likewise, theouter assembly550 can haveouter slots554, theinner assembly570 can haveinner slots574, andtubes540 can be constrained within individual ones of theouter slots554 and/orinner slots574. In the illustrated embodiment, however, theassemblies550,570 each include multiple cam rings (not pictured) that can be individually controlled and/or mechanically synchronized to permit all of thetubes540 to be positioned within the outer slots554 (e.g., as shown inFIG.5) or within the inner slots574 (e.g., as shown inFIG.6). Actuation of the multiple cam rings can simultaneously or discretely move thetubes540 between the inner andouter slots554,574. In some embodiments, using multiple cams per inner/outer assembly allows increased control of tube movement and timing.

As described above, cam rings in accordance with the present technology can have various periodic shapes for driving the drive members radially inward or outward.FIG.7, for example, is an enlarged top view of a cam ring772 (e.g., an inner cam ring) having anouter surface785 having a generally saw-tooth periodic shape including a plurality of (e.g., sharp, pointed, etc.) peaks787 andtroughs789.FIG.8, for example, is an enlarged top view of a cam ring872 (e.g., an inner cam ring) having anouter surface885 having a generally triangular or linear shape including a plurality of (e.g., blunted, flat, etc.) peaks887 andtroughs889. In other embodiments, cam rings in accordance with the present technology can other suitable periodic or non-periodic shapes for actuating the drive members.

FIG.9 is a screenshot of auser interface900 that can be used to control the system100 (FIG.1) and the characteristics of the resultingbraid105 formed on themandrel102. A plurality of clickable, pushable, or otherwise engageable buttons, indicators, toggles, and/or user elements is shown within theuser interface900. For example, theuser interface900 can include a plurality of elements each indicating a desired and/or expected characteristic for the resultingbraid105. In some embodiments, characteristics can be selected for one or more zones (e.g., the 7 illustrated zones) each corresponding to a different vertical portion of thebraid105 formed on themandrel102. More particularly,elements910 can indicate a length for the zone along the length of the mandrel or braid (e.g., in cm), elements920 can indicate a number of picks (a number of crosses) per cm, elements930 can indicate a pick count (e.g., a total pick count), elements940 can indicate a speed for the process (e.g., in picks formed per minute), and elements950 can indicate a braiding wire count. In some embodiments, if the user inputs a specific characteristic for a zone, some or all of the other characteristics may be constrained or automatically selected. For example, a user input of a certain number of “picks per cm” and zone “length” may constrain or determine the possible number of “picks per cm.” The user interface can further include selectable elements960 for pausing of thesystem100 after thebraid105 has been formed in a certain zone, andselectable elements970 for keeping the mandrel stationary during the formation of a particular zone (e.g., to permit manual jogging of themandrel102 rather than automatic). In addition, the user interface can includeelements980aand980bfor jogging the table,elements985aand985bfor jogging (e.g., raising or lowering) themandrel102 up or down, respectively,elements990aand990bfor loading a profile (e.g., a set of saved braid characteristics) and running a selected profile, respectively, and anindicator995 for indicating that a run (e.g., all or a portion of a braiding process) is complete.

In some embodiments, for example, lower pick counts improve flexibility, while higher pick counts increases longitudinal stiffness of thebraid105. Thus, thesystem100 advantageously permits for the pick count (and other characteristics of the braid105) to be varied within a specific length of thebraid105 to provide variable flexibility and/or longitudinal stiffness. For example,FIG.10 is an enlarged view of themandrel102 and thebraid105 formed thereon. Thebraid105 ormandrel102 can include a first zone Z1, a second zone Z2, and a third zone Z3 each having different characteristics. As shown, for example, the first zone Z1 can have a higher pick count than the second and third zones Z2 and Z3, and the second zone Z2 can have a higher pick count than third zone Z3. Thebraid105 can therefore have a varying flexibility—as well as pore size—in each zone.

EXAMPLES

Several aspects of the present technology are set forth in the following examples.

1. A braiding system, comprising:

• • a drive unit including—
    • an outer assembly including an outer cam and outer slots;
    • an inner assembly including an inner cam and inner slots, wherein the inner assembly is coaxially aligned with the outer assembly, and wherein the number of inner and outer slots is the same;
  • a plurality of tubes, wherein individual ones of the tubes are constrained within individual ones of the inner and/or outer slots;
  • an outer drive mechanism configured to rotate the outer cam to drive a first set of the tubes from the outer slots to the inner slots; and
  • an inner drive mechanism configured to rotate the inner cam to drive a second set of the tubes from the inner slots to the outer slots.

2. The braiding system of example 1 wherein—

• • when the first set of tubes is constrained within the outer slots, the second set of tubes is constrained within the inner slots; and
  • when the first set of tubes is constrained within the inner slots, the second set of tubes is constrained within the outer slots.

3. The braiding system of example 1 or 2 wherein the inner and outer drive mechanisms are configured to rotate the inner and outer cams to substantially simultaneously (a) drive the first set of the tubes from the outer slots to the inner slots and (b) drive the second set of the tubes from the inner slots to the outer slots.

4. The braiding system of any one of examples 1-3 wherein—

• • the outer assembly includes outer drive members aligned with the outer slots;
  • the inner assembly includes inner drive members aligned with the inner slots;
  • the outer drive mechanism is configured to rotate the outer cam to move the outer drive members radially inward; and
  • the inner drive mechanism is configured to rotate the inner cam to move the inner drive members radially outward.

5. The braiding system of example 4 wherein—

• • a first rotational movement of the outer cam moves a first set of the outer drive members radially inward; and
  • a second rotational movement of the outer cam moves a second set of the outer drive members radially inward.

6. The braiding system of example 5 wherein the first and second sets of the outer drive members include the same number of outer drive members.

7. The braiding system of any one of examples 4-6 wherein—

• • a first rotational movement of the inner cam moves a first set of the inner drive members radially outward; and
  • a second rotational movement of the inner cam moves a second set of the inner drive members radially outward.

8. The braiding system of any one of examples 4-7 wherein the first and second sets of the inner drive members include the same number of inner drive members.

9. The braiding system of any one of examples 4-8 wherein—

• • the outer cam has a radially-inward facing surface with a periodic shape that is in continuous contact with the outer drive members; and
  • the inner cam has a radially-outward facing surface with a periodic shape that is in continuous contact with the inner drive members.

10. The braiding system of any one of examples 1-9 wherein the inner and outer assemblies are substantially coplanar, and wherein the inner assembly is rotatable relative to the outer assembly.

11. A method of forming a tubular braid, the method comprising:

• • rotating an inner assembly relative to an outer assembly, wherein the inner assembly constrains a first set of elongate members, wherein the outer assembly constrains a second of elongate members, and wherein individual ones of the first and second elongate members are configured to receive individual filaments; and
  • substantially simultaneously—
    • driving an inner cam of the inner assembly to move the first set of elongate members from the inner assembly to the outer assembly; and
    • driving an outer cam of the outer assembly to move the second set of elongate members from the outer assembly to the inner assembly.

12. The method of example 11 further comprising, after substantially simultaneously driving the inner and outer cams, rotating the inner assembly to rotate the second set of elongate members relative to the first set of elongate members.

13. The method of example 11 or 12 wherein rotating the inner assembly includes rotating the inner assembly in a first direction to rotate the first set of elongate members relative to the second set of elongate members, and wherein the method further comprises:

• • after substantially simultaneously driving the inner and outer cams, rotating the inner assembly in a second direction to rotate the second set of elongate members relative to the first set of elongate members, wherein the first direction is opposite to the second direction.

14. The method of any one of examples 11-13 wherein—

• • the inner assembly includes inner slots configured to constrain the first set or the second set of the elongate members;
  • the outer assembly includes outer slots configured to constrain the first set or the second set of the elongate members; and
  • the number of inner and outer slots is the same.

15. A braiding system, comprising:

• • a plurality of elongate members each having an upper portion and a lower portion, wherein individual ones of the elongate members are configured to receive individual filaments;
  • an upper drive unit configured to act against the upper portions of the elongate members; and
  • a lower drive unit coaxially aligned with the upper drive unit along a longitudinal axis and configured to act against the lower portions of the elongate members,
  • wherein the upper and lower drive units are configured to act against the upper and lower portions of the elongate members in synchronization to simultaneously drive (a) a first set of the elongate members radially inward toward the longitudinal axis and (b) a second set of the elongate members radially outward away from the longitudinal axis.

16. The braiding system of example 15 wherein the upper drive unit constrains the upper portions of the elongate members, and wherein the lower drive unit constrains the lower portions of the elongate members.

17. The braiding system of example 15 or 16 wherein the upper and lower drive units are further configured to move the elongate members along an arcuate path with respect to the longitudinal axis.

18. The braiding system of any one of examples 15-17 wherein the upper and lower drive units are substantially identical.

19. The braiding system of any one of examples 15-18 wherein the upper and lower drive units are mechanically synchronized to move together.

20. The braiding system of any one of examples 15-19 wherein—

• • the upper drive unit includes (a) an outer assembly having outer slots and (b) an inner assembly having inner slots;
  • the lower drive unit includes (a) an outer assembly having outer slots and (b) an inner assembly having inner slots;
  • individual ones of the elongate members are constrained within individual ones of the inner and/or outer slots of the upper and lower drive units; and
  • the number of inner and outer slots is the same.
    Conclusion

The above detailed descriptions of embodiments of the technology are not intended to be exhaustive or to limit the technology to the precise form disclosed above. Although specific embodiments of, and examples for, the technology are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology as those skilled in the relevant art will recognize. For example, although steps are presented in a given order, alternative embodiments may perform steps in a different order. The various embodiments described herein may also be combined to provide further embodiments.

From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the technology. Where the context permits, singular or plural terms may also include the plural or singular term, respectively.

Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in reference to a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of the items in the list. Additionally, the term “comprising” is used throughout to mean including at least the recited feature(s) such that any greater number of the same feature and/or additional types of other features are not precluded. It will also be appreciated that specific embodiments have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. Further, while advantages associated with some embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.

Claims (13)

We claim:

1. A braiding system, comprising:

a drive unit including

an outer assembly including an outer cam, outer slots, and outer drive members aligned with the outer slots;

an inner assembly including an inner cam, inner slots, and inner drive members aligned with the inner slots, wherein the inner assembly is coaxially aligned with the outer assembly, and wherein the number of inner and outer slots is the same;

a plurality of tubes, wherein individual ones of the tubes are constrained within individual ones of the inner and/or outer slots;

an outer drive motor configured to rotate the outer cam to move the outer drive members radially inward to drive a first set of the tubes from the outer slots to the inner slots; and

an inner drive motor configured to rotate the inner cam to move the inner drive members radially outward to drive a second set of the tubes from the inner slots to the outer slots, wherein the inner and outer drive motors are configured to rotate the inner and outer cams to simultaneously (a) move the outer drive members radially inward to drive the first set of the tubes from the outer slots to the inner slots and (b) move the inner drive members radially outward to drive the second set of the tubes from the inner slots to the outer slots.

2. The braiding system ofclaim 1 wherein—

when the first set of tubes is constrained within the outer slots, the second set of tubes is constrained within the inner slots; and

when the first set of tubes is constrained within the inner slots, the second set of tubes is constrained within the outer slots.

3. The braiding system ofclaim 1 wherein—

a first rotational movement of the outer cam moves a first set of the outer drive members radially inward; and

a second rotational movement of the outer cam moves a second set of the outer drive members radially inward.

4. The braiding system ofclaim 3 wherein the first and second sets of the outer drive members include the same number of outer drive members.

5. The braiding system ofclaim 1 wherein—

a first rotational movement of the inner cam moves a first set of the inner drive members radially outward; and

a second rotational movement of the inner cam moves a second set of the inner drive members radially outward.

6. The braiding system ofclaim 5 wherein the first and second sets of the inner drive members include the same number of inner drive members.

7. The braiding system ofclaim 1 wherein—

the outer cam has a radially-inward facing surface with a periodic shape that is in continuous contact with the outer drive members; and

the inner cam has a radially-outward facing surface with a periodic shape that is in continuous contact with the inner drive members.

8. The braiding system ofclaim 1 wherein the inner and outer assemblies are substantially coplanar, and wherein the inner assembly is rotatable relative to the outer assembly.

9. The braiding system ofclaim 1, further comprising:

a plurality of weights positioned within corresponding ones of the tubes;

wherein individual ones of the tubes are configured to receive individual filaments; and

wherein the weights are configured to be secured to corresponding ones of the filaments within the tubes.

10. A method of forming a tubular braid, the method comprising:

rotating an inner assembly relative to an outer assembly, wherein the inner assembly constrains a first set of elongate members, wherein the outer assembly constrains a second set of the elongate members, and wherein individual ones of the elongate members in the first set and individual ones of the elongate members in the second set are configured to receive individual filaments; and

simultaneously—

rotating an inner cam of the inner assembly to move a plurality of outer drive members radially inward to move the first set of elongate members from the inner assembly to the outer assembly; and

rotating an outer cam of the outer assembly to move a plurality of inner drive members radially outward to move the second set of elongate members from the outer assembly to the inner assembly.

11. The method ofclaim 10 further comprising, after simultaneously rotating the inner and outer cams, rotating the inner assembly to rotate the second set of elongate members relative to the first set of elongate members.

12. The method ofclaim 10 wherein rotating the inner assembly includes rotating the inner assembly in a first direction to rotate the first set of elongate members relative to the second set of elongate members, and wherein the method further comprises:

after simultaneously rotating the inner and outer cams, rotating the inner assembly in a second direction to rotate the second set of elongate members relative to the first set of elongate members, wherein the first direction is opposite to the second direction.

13. The method ofclaim 10 wherein—

the inner assembly includes inner slots configured to constrain the first set or the second set of the elongate members;

the outer assembly includes outer slots configured to constrain the first set or the second set of the elongate members; and

the number of inner and outer slots is the same.

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